Chatter Suppression of External Grooving Tools

Generating deep grooves using long blades is a challenge due to excessive chatter vibrations. In the present paper, an analytical simplified solution of the critical grooving width is obtained. It is found that a cross FRF of the tool dominates the solution. A conventional grooving tool with long overhang is tested where chatter vibrations develop. A new tool with attached Dynamic Vibration Absorber (DVA) is designed to replace the conventional one and a novel DVA tuning mechanism is presented. The cross FRF real part is optimized via modal experiments and the tuning mechanism. Machining experiments are conducted for both grooving systems in order to verify the model predictions. Grooving is unstable using the conventional blade while it is stable with the tuned new one.